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Table of Contents
This owner's manual contains
important safety information.
Please read it carefully.
Part No. 99011-40H50-03A
July, 2008


Table of Contents


   Also See for Suzuki VZ1500

   Summary of Contents for Suzuki VZ1500

  • Page 1 VZ1500 OWNER’S MANUAL This owner’s manual contains important safety information. Please read it carefully. Part No. 99011-40H50-03A July, 2008...
  • Page 2 California Proposition 65 Warning WARNING Engine exhaust, some of its constituents, and certain product com- ponents contain or emit chemicals known to the State of California to cause cancer and birth defects or other reproductive harm. This manual should be considered a permanent part of the motorcycle and should remain with the motorcycle when resold or otherwise transferred to a new owner or operator.
  • Page 3 IMPORTANT NOTE: Indicates special information to make maintenance easier or instruc- tions clearer. WARNING/CAUTION/NOTE Please read this manual and follow its WARNINGs CAUTIONs instructions carefully. To emphasize arranged like this: special information, the symbol  and the words WARNING, CAUTION and ...
  • Page 4 FOREWORD ance. Your authorized Suzuki dealer has experienced technicians that are trained to provide your machine with the Motorcycling is one of the most exhila- best possible service with the right tools rating sports and to ensure your riding and equipment.
  • Page 5 Due to improvements or other changes, there may be some discrepancies between information in this manual and your motorcycle. Suzuki reserves the right to make production changes at any time, without notice and without incurring any obligation to make the same or similar changes to vehicles previously built or sold.
  • Page 7: Table Of Contents

  • Page 10: The Sport Of Motorcycling

    THE SPORT OF In preparing for these challenges, you will be fine-tuning your coordination, MOTORCYCLING concentration, and attitude. Learning the skills and strategies associated with Your motorcycle and this owner’s man- motorcycling is the basis for safely par- ual have been designed by people like ticipating in this sport.
  • Page 11: Most Accidents Can Be Avoided

    MOST ACCIDENTS CAN BE AVOIDED IF YOU DON’T HAVE A HELMET - BUY The most common type of motorcycle A HELMET, AND WEAR IT EVERY accident in the U.S. occurs when a car TIME YOU RIDE traveling toward a motorcycle turns left Most accidents occur within a few miles in front of the motorcycle.
  • Page 12: If A Collision Is Imminent, Do Something

    IF A COLLISION IS IMMINENT, DO Emergency stopping and swerving are techniques that you should practice and SOMETHING! master before you find yourself in an Many riders fear locking up their brakes emergency situation. The best place to or haven’t learned to swerve to avoid an practice such techniques is in a con- accident.
  • Page 13: Special Situations Require Special Care

    SPECIAL SITUATIONS REQUIRE KNOW YOUR LIMITS SPECIAL CARE Always ride within the boundaries of your own skills. Knowing these limits Of course, there are some times when and staying within them will help you full-force braking is not the correct tech- avoid accidents.
  • Page 14: Be Extra Safety-conscious On Bad Weather Days

    Riding a motorcycle safely requires that BE EXTRA SAFETY-CONSCIOUS ON your mental and physical skills are fully BAD WEATHER DAYS part of the experience. You should not Riding on bad weather days, especially attempt to operate a motor vehicle, wet ones, requires extra caution. Brak- especially one with two wheels, if you ing distances increase on a rainy day.
  • Page 15: Practice Away From Traffic

    PRACTICE AWAY FROM TRAFFIC INSPECTION BEFORE RIDING Your riding skill and your mechanical Review the instructions in the INSPEC- knowledge form the foundation for safe TION BEFORE RIDING section of this riding practices. We suggest that you manual. Perform an entire pre-ride practice riding your motorcycle in a non- inspection before you head out on the traffic situation until you are thoroughly...
  • Page 16: Accessories And Loading

    ACCESSORIES AND LOADING CARRYING A PASSENGER The accessories you use with your Carrying a passenger, when done cor- motorcycle and the manner in which rectly, is a great way to share the joy of you load your gear onto the bike might motorcycling.
  • Page 17: Motorcycle Safety Foundation's "riding Tips And Practice Guide" Handbook (for Owners In Usa)

    MOTORCYCLE SAFETY BE STREET SMART FOUNDATION’S Always heed speed limits, local laws, and the basic rules of the road. Set a “RIDING TIPS AND PRACTICE GUIDE” good example for others by demonstrat- HANDBOOK ing a courteous attitude and a responsi- (FOR OWNERS IN USA) ble riding style.
  • Page 18: Conclusion

    Motorcycle dictable. Your motorcycle’s condition Safety Foundation. Your authorized can change. These factors can best be Suzuki dealer can help you locate the dealt with by giving every ride your full fundamental or advanced riding skills attention.
  • Page 19: Fuel, Oil And Coolant Recommendations

    FUEL, OIL AND COOLANT RECOMMENDATIONS FUEL ................................2-2 ENGINE OIL ..............................2-5 FINAL GEAR OIL ............................2-7 ENGINE COOLANT SOLUTION ........................ 2-7...
  • Page 20: Fuel

    FUEL, OIL AND COOLANT Gasoline containing MTBE Unleaded gasoline containing MTBE RECOMMENDATIONS (Methyl Tertiary Butyl Ether) may be used in your motorcycle if the MTBE FUEL content is not greater than 15%. This Your motorcycle requires regular oxygenated fuel does not contain alco- unleaded gasoline with a minimum hol.
  • Page 21 Suzuki and may not be genate and additives. If you are not covered under the New Vehicle Limited...
  • Page 22 NOTE: CAUTION • help minimize pollution, Suzuki recommends that you use Spilled gasoline containing alcohol oxygenated fuels. can harm your motorcycle. Alcohol • Be sure that any oxygenated fuel can damage painted surfaces. you use has octane ratings of at...
  • Page 23: Engine Oil

    ENGINE OIL SAE Engine Oil Viscosity Suzuki recommends the use of SAE Oil quality is a major contributor to your 10W-40 engine oil. If SAE 10W-40 engine’s performance and life. Always engine oil is not available, select an select good quality engine oil. Suzuki...
  • Page 24 JASO T903 Energy Conserving The JASO T903 standard is an index to Suzuki does not recommend the use of select engine oils for 4-stroke motorcy- “ENERGY CONSERVING” oils. Some cle and ATV engines. Motorcycle and engine oils which have an API classifi-...
  • Page 25: Final Gear Oil

    FINAL GEAR OIL ENGINE COOLANT SOLUTION Use an SAE90 hypoid gear oil which is Use engine coolant that is compatible rated GL-5 under the API classification with an aluminum radiator, mixed with system. If you operate the motorcycle distilled water at a 50:50 mixture ratio where ambient temperature is below for engine coolant solution.
  • Page 26  WARNING CAUTION Engine coolant is harmful or fatal if Spilled engine coolant can damage swallowed or inhaled. painted surfaces. Do not drink antifreeze or coolant Do not spill any fluid when filling the solution. If swallowed, do not induce radiator.
  • Page 27: Controls, Equipment And Adjustments

    CONTROLS, EQUIPMENT AND ADJUSTMENTS LOCATION OF PARTS ..........................3-2 KEY ................................3-5 IGNITION SWITCH ............................. 3-6 STEERING LOCK ............................3-7 INSTRUMENT PANEL ..........................3-8 LEFT HANDLEBAR ..........................3-21 RIGHT HANDLEBAR ..........................3-24 FUEL TANK CAP ............................3-28 GEARSHIFT LEVER ..........................3-30 REAR BRAKE PEDAL ..........................
  • Page 28: Controls, Equipment And Adjustments

    CONTROLS, EQUIPMENT AND ADJUSTMENTS LOCATION OF PARTS Clutch lever Right handlebar switches Left handlebar switches Throttle grip Instrument panel Front brake lever Indicator lights Fuel tank cap Front brake fluid reservoir...
  • Page 29 Air cleaner Footrests Spark plug Engine oil filler cap Ignition switch Engine oil drain plug Battery and Main fuse Speed sensor Tools Side stand Helmet holder Engine coolant reservoir Gearshift lever Passenger footrests Engine oil filter...
  • Page 30 Fuses Rear brake fluid reservoir Steering lock Seat lock Rear brake light switch Rear brake pedal...
  • Page 31: Key

    Please write down your key number in the box provided for your future refer- ence. Key number: Two keys come with this motorcycle. Keep the spare key in a safe place. An identifying number is stamped on the plate. Use this number when making a replacement key.
  • Page 32: Ignition Switch

    IGNITION SWITCH “ON” position The ignition circuit is completed and the engine can be started. The headlight, front turn signal light and taillight will automatically turn on. The key cannot be removed in this position. NOTE: Start the engine promptly after turning the key to the “ON”...
  • Page 33: Steering Lock

    STEERING LOCK WARNING Moving the motorcycle while the steering is locked can be hazardous. You could lose your balance and fall, or you could drop the motorcycle. Never attempt to move the motorcy- cle when the steering is locked. Turn the handlebars all the way to the left.
  • Page 34: Instrument Panel

    INSTRUMENT PANEL The coolant temperature indicator light oil pressure indicator light 4, fuel injection system indicator light 8 LCD’s and speedometer needle work as follows to confirm their function when the ignition switch is turned to the “ON” position. • The coolant temperature indicator light 3, oil pressure indicator light 4, and fuel injection system indica-...
  • Page 35 COMBINATION SYSTEM DISPLAY 2 SPEEDOMETER 1 The speedometer indicates the road The display in the speedometer has five speed in kilometers per hour and miles functions, odometer, two trip meters, clock and fuel meter. When the ignition per hour. switch is turned to the “ON” position, If the speedometer needle does not the test pattern shown below is dis- point to zero, follow the procedure...
  • Page 36 Odometer TRIP Trip meter 1 TRIP Trip meter 2 Clock 3-10...
  • Page 37 Odometer NOTE: When the trip meter exceeds The odometer registers the total dis- 9999.9, the trip meter will return to 0.0 tance that the motorcycle has been rid- and start counting again. den. The odometer ranges from 0 to  WARNING 999999 miles.
  • Page 38 Clock 2 seco nd s Pu sh 2 seco nd s 2 seco nd s 3-12...
  • Page 39 The clock has a 12-hour display. Follow  WARNING the procedure below to adjust the clock. Operating the display while riding 1. Press and hold the button 9 for 2 can be hazardous. Removing a hand seconds until the clock display from the handlebars can reduce your blinks.
  • Page 40 Fuel Meter “” The fuel meter indicates the amount of fuel remaining in the fuel tank. The fuel meter displays all 5 segments when the fuel tank is full. The mark flickers when the fuel level drops below 3.5 L (3.7 US qt).
  • Page 41 NOTE: Check the fuel meter with the COOLANT TEMPERATURE INDICATOR LIGHT “” 3 motorcycle held vertically. Fuel meter does not indicate correctly when the This indicator comes on when the cool- motorcycle is placed on the side stand. ant temperature is too high. CAUTION Running the engine with high engine coolant temperature can cause seri-...
  • Page 42 OIL PRESSURE INDICATOR LIGHT “” 4 This indicator comes on when the engine oil pressure is below the normal operating range. This should come on when the ignition switch is “ON” and the engine is not running. As soon as the engine starts, this indicator should go out.
  • Page 43 If the light still does not go out, have your authorized SUZUKI dealer or a qualified mechanic troubleshoot your motorcycle.
  • Page 44 HIGH BEAM INDICATOR LIGHT “” The blue indicator light will come on when the headlight high beam is turned NEUTRAL INDICATOR LIGHT “N” 7 The green light will come on when the transmission is in neutral. The light will go out when you shift into any gear other than neutral.
  • Page 45 Whenever the red indicator light is lit mileage/clock alternately and the and the display indicates “FI”, have red indicator light 8 comes on and your authorized Suzuki dealer or a remains lit. qualified mechanic inspect the fuel injection system as soon as possi- B.
  • Page 46 If the display 2 indicates “FI” and • mileage/clock alternately, keep the engine running and bring your motorcycle to an authorized Suzuki dealer. If the engine stalls, try restarting the engine after turning the ignition switch off and on. If the display 2 indicates “FI” contin- •...
  • Page 47: Left Handlebar

    LEFT HANDLEBAR When the display 2 indicates “CHEC”, check following items; • Make sure that the engine stop switch is in the “” position. • Make sure that the transmission is in neutral or the side stand is fully up. Clutch Lever 1 If the display still indicates “CHEC”...
  • Page 48 CAUTION Holding the dimmer switch between “” and “” position will light both “” and “” headlight beam. This operation can damage the motorcycle. Use the dimmer switch only at “” Dimmer Switch 3 or “” position. “” position The headlight low beam and taillight CAUTION turn on.
  • Page 49 Turn Signal Switch “ ” 4 Horn Button “” 5 Moving the switch to the “” position Press the button to sound the horn. will flash the left turn signals. Moving Hazard Warning Switch “” 6 the switch to the “” position will flash the right turn signals.
  • Page 50: Right Handlebar

    Front Brake Lever 2 RIGHT HANDLEBAR Apply the front brake by squeezing the front brake lever toward the grip. The brake light will come on when the lever is squeezed. Engine Stop Switch 1 “” position The ignition circuit is off. The engine cannot start or run.
  • Page 51 Front Brake Lever Adjustment  WARNING Adjusting the front brake lever posi- tion while riding can be hazardous. Removing a hand from the handle- bars can reduce your ability to con- trol the motorcycle. Always keep both hands on the han- dlebars while riding.
  • Page 52 Electric Starter Button “” 3 Use this button to operate the starter motor. With the ignition switch in the “ON” position, the engine stop switch in the “” position, and the transmission in neutral, pull in the clutch lever and push the electric starter button to start the engine.
  • Page 53 Throttle Grip 4 CAUTION Engine speed is controlled by the posi- tion of the throttle grip. Turn it toward To prevent electrical system damage, you to increase engine speed. Turn it do not operate the starter motor away from you to decrease engine longer than five seconds at a time.
  • Page 54: Fuel Tank Cap

    FUEL TANK CAP Face the arrow mark forward when refit- ting the fuel tank cap. To open the fuel tank cap, insert the ignition key into the lock and turn it clockwise. With the key inserted, lift the cap up with key. To close the fuel tank cap, push the cap down firmly with the key in the cap lock.
  • Page 55  WARNING Fuel and fuel vapor are highly flam- mable and toxic. You can be burned or poisoned when refueling. • Stop the engine and keep flames, sparks and heat sources away. • Refuel only outdoors or in a well Fuel level ventilated area.
  • Page 56: Gearshift Lever

    GEARSHIFT LEVER NOTE: When the transmission is in neutral, the green indicator light on the instrument panel will be lit. However, even though the light is lit, cautiously and slowly release the clutch lever to make sure that the transmission is posi- tively in neutral.
  • Page 57: Rear Brake Pedal

    REAR BRAKE PEDAL SEAT LOCK Pressing the rear brake pedal will apply 1. Unhook the hooks and remove the the rear brake. The brake light will come right side frame cover. on when the rear brake is operated. 3-31...
  • Page 58 2. To remove the seat, insert the igni- 3. Raise the rear end of the seat and tion key into the lock and turn it slide it backward. clockwise. 3-32...
  • Page 59  WARNING Failure to install the seat properly could allow the seat to move and cause loss of rider control. Latch the seat securely in its proper position. To reinstall the seat, slide the seat hook into the seat hook retainer and push down firmly until the seat snaps into the locked position.
  • Page 60: Helmet Holder

    HELMET HOLDER  WARNING Riding with a helmet fastened to the helmet holder can interfere with rider control. Never carry a helmet fastened to the helmet holder. helmet securely atop the seat if you must carry it. The helmet holder is located on the left side below the rear seat.
  • Page 61: Side Stand

    SIDE STAND The side stand/ignition interlock sys- tem works as follows: • If the side stand is down and the transmission is in gear, the engine cannot be started. • If the engine is running and the transmission is shifted into gear with the side stand down, the engine will stop running.
  • Page 62  WARNING CAUTION Riding with the side stand incom- Park the motorcycle on firm, level pletely retracted can result in an ground to help prevent it from falling accident when you turn left. over. • Check operation of the side stand/ ignition interlock system before If you must park on an incline, aim riding.
  • Page 63: Suspension Adjustment

    SUSPENSION ADJUSTMENT REAR SUSPENSION Spring Pre-load Adjustment 1. Place the motorcycle on the side stand. 3. Remove the bolts and left side lower cover. 2. Unhook the hooks and remove the left side frame cover. 3-37...
  • Page 64 4. This adjustment can be performed by changing the adjuster ring posi- tion. However, Suzuki recommends that this adjustment be done by your authorized Suzuki dealer, since a special tool is needed for this job. 3-38...
  • Page 67: Break-in And Inspection Before Riding

    BREAK-IN AND INSPECTION BEFORE RIDING BREAK-IN ..............................4-2 INSPECTION BEFORE RIDING ......................... 4-5...
  • Page 68 BREAK-IN AND INSPECTION Maximum Throttle Opening Recommendation BEFORE RIDING The table below shows the maximum throttle opening recommendation dur- BREAK-IN ing the break-in period. The first 800 km (500 miles) is the most important in the life of your motorcycle. Initial 800 km Less than Proper operation during this break-in...
  • Page 69 Breaking in the New Tires  WARNING New tires need proper break-in to assure maximum performance, just as Failure to perform break-in of the the engine does. Wear in the tread sur- tires could cause tire slip and loss of face by gradually increasing your cor- control.
  • Page 70 Allow the Engine Oil to Circulate Observe Your Initial and Most Critical before Riding Service Allow enough idling time after warm or The initial service (1000 km mainte- cold engine start-up before revving the nance) is the most important service engine or placing the transmission in your motorcycle will receive.
  • Page 71 INSPECTION BEFORE RIDING  WARNING  WARNING Using worn, improperly inflated, or incorrect tires will reduce stability Failure to inspect and maintain your and can cause an accident. motorcycle properly increases the chance of an accident or equipment Follow all instructions in the TIRES damage.
  • Page 72 Check the condition of the motorcycle  WARNING to help make sure that you do not have mechanical problems or get stranded Checking maintenance items when somewhere when you ride. Before the engine is running can be hazard- riding the motorcycle, be sure to check ous.
  • Page 73 Engine stop Proper operation WHAT TO CHECK FOR: switch CHECK Horn Correct function Steering • Smoothness • No restriction of movement Engine oil Correct level • No play or looseness Cooling • Proper coolant level Brakes • Proper pedal and lever system •...
  • Page 75: Riding Tips

    RIDING TIPS STARTING THE ENGINE ........................... 5-2 STARTING OFF AND SHIFTING ....................... 5-4 USING THE TRANSMISSION ........................5-6 RIDING ON HILLS ............................5-8 STOPPING AND PARKING ........................5-8 CARRYING A PASSENGER ........................5-11...
  • Page 76: Starting The Engine

    RIDING TIPS When the Engine is Cold: 1. Close the throttle completely. 2. Squeeze the clutch lever and push STARTING THE ENGINE the electric starter button. Before attempting to start the engine, 3. After the engine starts, let the make sure: engine run until the engine suffi- •...
  • Page 77 When the Engine is Hard to Start: CAUTION Open the throttle 1/8 to 1/4 turn and push the electric starter button. Running the engine too long without riding may cause the engine to over-  WARNING heat. Overheating can result in dam- age to internal engine components Running the engine indoors or in a and discoloration of exhaust pipes.
  • Page 78: Starting Off And Shifting

    STARTING OFF AND SHIFTING  WARNING  WARNING Removing your hands from the han- dlebars or feet from the footrests Riding this motorcycle at excessive during operation can be hazardous. speed increases your chances of los- If you remove even one hand or foot ing control of the motorcycle.
  • Page 79 Make sure that the side stand is in the  WARNING fully up position. Pull the clutch lever in and pause momentarily. Engage first Sudden side winds, which can occur gear by depressing the gearshift lever when being passed by larger vehi- downward.
  • Page 80: Using The Transmission

    USING THE TRANSMISSION Shifting up schedule The transmission is provided to keep Gear position miles/h km/h the engine operating smoothly in its 1st → 2nd normal operating speed range. The gear ratios have been carefully chosen 2nd → 3rd to meet the characteristics of the 3rd →...
  • Page 81  WARNING  WARNING Downshifting when engine speed is Downshifting while the motorcycle is too high can: leaned over in a corner may cause • cause the rear wheel to skid and rear wheel skid and loss of control. lose traction due to increased engine braking, resulting in an Reduce your speed and downshift accident;...
  • Page 82: Riding On Hills

    RIDING ON HILLS STOPPING AND PARKING • When climbing steep hills, the 1. Turn the throttle grip away from you motorcycle may begin to slow down to close the throttle completely. and show lack of power. At this point 2. Apply the front and rear brakes you should shift to a lower gear so evenly and at the same time.
  • Page 83  WARNING  WARNING Inexperienced riders tend Hard braking on wet, loose, rough, or underutilize the front brake. This can other slippery surfaces can cause cause excessive stopping distance wheel skid and loss of control. and lead to a collision. Using only the front or rear brake can cause Brake lightly and with care on slip- skidding and loss of control.
  • Page 84 5. Park the motorcycle on a firm, flat  WARNING surface where it will not fall over. 6. Turn the ignition switch to the “OFF” A hot muffler can burn you. The muf- position. fler will be hot enough to burn you 7.
  • Page 85: Carrying A Passenger

    CARRYING A PASSENGER To help prevent burn injuries, warn your passenger not to contact the muffler Before you invite someone to be a pas- when mounting or dismounting your senger on your motorcycle, you need to motorcycle. be thoroughly familiar with motorcycle operation.
  • Page 87: Accessory Use And Motorcycle Loading

    ACCESSORY USE AND MOTORCYCLE LOADING ACCESSORY USE ............................. 6-2 ACCESSORY INSTALLATION GUIDELINE ....................6-3 LOADING LIMIT ............................6-4 LOADING GUIDELINES ..........................6-5 MODIFICATION ............................6-6...
  • Page 88: Accessory Use

    The addition of unsuitable accessories can lead to an accident. can lead to unsafe operating conditions. It is not possible for Suzuki to test each Use Suzuki genuine accessories or accessory on the market or combina- equivalent, designed and tested for tions of all the available accessories;...
  • Page 89: Accessory Installation Guideline

    ACCESSORY INSTALLATION • Accessories fitted to the handlebars or the front fork area can create seri- GUIDELINE ous stability problems. The extra • Install aerodynamic affecting acces- weight will cause the motorcycle to sories, such as a fairing, windshield, be less responsive to your steering backrests, saddlebags, and travel control.
  • Page 90: Loading Limit

    • Additional electrical accessories LOADING LIMIT may overload the existing electrical  WARNING system. Severe overloads may dam- age the wiring harness or create a Overloading or improper loading can hazardous situation due to the loss cause loss of motorcycle control and of electrical power during the opera- this may result in an accident.
  • Page 91: Loading Guidelines

    GVWR: 550 kg (1210 lbs) at the tire LOADING GUIDELINES pressure (cold) This motorcycle is primarily intended to Front: 250 kPa (2.50 kgf/cm , 36 psi) carry small items when you are not Rear: 290 kPa (2.90 kgf/cm , 42 psi) riding with a passenger.
  • Page 92: Modification

    • Improperly loading your motorcycle MODIFICATION can reduce your ability to balance Modification of the motorcycle, or and steer the motorcycle. You removal of original equipment may ren- should ride at reduced speeds, less der the vehicle unsafe or illegal. Obey than 130 km/h (80 mph), when you all applicable equipment regulations in are carrying cargo or have added...
  • Page 93: Inspection And Maintenance

    INSPECTION AND MAINTENANCE NOTICE ............................... 7-2 MAINTENANCE SCHEDULE ........................7-2 TOOLS ................................ 7-7 GENERAL LUBRICATION ......................... 7-7 BATTERY ..............................7-9 AIR CLEANER ............................7-11 SPARK PLUG ............................7-18 ENGINE OIL .............................. 7-23 THROTTLE CABLE ADJUSTMENT ......................7-31 ENGINE IDLE SPEED INSPECTION ....................... 7-32 FUEL HOSE ..............................
  • Page 94: Notice

    INSPECTION AND MAINTENANCE SCHEDULE It is very important to inspect and main- MAINTENANCE tain your motorcycle regularly. Follow the guidelines in the chart. The intervals NOTICE between periodic services in kilometers, miles and months are shown. At the MAINTENANCE, REPLACEMENT end of each interval, be sure to perform OR REPAIR OF THE EMISSION the maintenance listed.
  • Page 95 Only run the engine outdoors where schedules in this owner’s manual. there is fresh air. Ask your SUZUKI dealer or a quali- fied mechanic to do the maintenance NOTE: The MAINTENANCE CHART items marked with an asterisk (*).
  • Page 96 CAUTION Using poor quality replacement parts can cause your motorcycle to wear more quickly and may shorten its useful life. Use only genuine SUZUKI replace- ment parts or their equivalent.
  • Page 97 MAINTENANCE CHART Interval: This interval should be judged by odometer reading or number of months, whichever comes first. Interval 1000 6000 12000 18000 24000 mile 4000 7500 11000 14500 Element months Air cleaner element – * Exhaust pipe bolts and muffler bolts –...
  • Page 98 Interval 1000 6000 12000 18000 24000 mile 4000 7500 11000 14500 Element months Clutch cable play – * Brakes – Brake hose * Replace every 4 years – Brake fluid * Replace every 2 years Tires – * Steering – –...
  • Page 99: Tools

    TOOLS GENERAL LUBRICATION Proper lubrication is important for safe, smooth operation and a long life for your motorcycle. Be sure that all lubri- cation is performed during periodic maintenance motorcycle. Increase frequency when you use your motorcycle in severe conditions. CAUTION Lubricating switches can damage A tool kit is provided with your motorcy-...
  • Page 100 1 Clutch lever holder 2 Gearshift link pivots 3 Side stand pivot and spring hook 4 Brake lever holder 5 Brake pedal pivot  ... Grease...
  • Page 101: Battery

    BATTERY  WARNING The battery is a sealed type battery and requires no maintenance. The standard Hydrogen gas produced by batteries charging rate is 1.8A × 5 to 10 hours can explode if exposed to flames or and the maximum rate is 9.0A × 1 hour. sparks.
  • Page 102 Battery Removal 4. To reinstall the battery, reverse the 1. Place the motorcycle on the side procedure above. stand. 2. Remove the seat by referring to the CAUTION SEAT LOCK section. Reversing the battery lead wires can damage the charging system and the battery.
  • Page 103: Air Cleaner

    AIR CLEANER  WARNING The air cleaner element must be kept clean to provide good engine power and Operating the engine without the air gas mileage. If you use your motorcycle cleaner element in place could allow under normal low stress conditions, you a flame to spit back from the engine should service the air cleaner at the to the air cleaner, or could allow dirt...
  • Page 104 Air Cleaner Element Removal CAUTION 1. Place the motorcycle on the side stand. Inspect or replace the air cleaner ele- ment frequently if the motorcycle is used in dusty, wet or muddy condi- tions. The air cleaner element will clog under these conditions, and this may cause engine damage, poor per- formance, and poor fuel economy.
  • Page 105 3. Loosen the clamp screw 3 and 4. Disconnect the tubes 5 and coupler remove the air cleaner 4. 7-13...
  • Page 106 5. Remove the screws. Remove the air 6. Remove the screws. Remove the air cleaner case 7. cleaner element 8. 7-14...
  • Page 107 CAUTION A torn air cleaner element will allow dirt to enter the engine and can dam- age the engine. Carefully examine the air cleaner ele- ment for tears during cleaning. Replace it with a new one if it is torn. 7.
  • Page 108 8. Reinstall the air cleaner element in Air Cleaner Drain Plug reverse order of removal. Be sure that the air cleaner element is securely in position and is properly sealed. CAUTION Failure to position the air cleaner ele- ment properly can allow dirt to bypass the air cleaner element.
  • Page 109 Remove the plug and drain water and oil at the periodic maintenance interval. The air cleaner drain plugs are located inside the air cleaner box and air cleaner left chamber side. LEFT 7-17...
  • Page 110: Spark Plug

    Consult your type may be needed. Consult your authorized SUZUKI dealer or a quali- authorized Suzuki dealer or a qualified fied mechanic if you are not sure mechanic if your plug insulator is not a which spark plug is correct for your light brown color.
  • Page 111 If the standard plug is with your motorcycle’s ignition system, CR7E U22ESR-N apt to overheat, replace with this plug. resulting in motorcycle performance problems. Use only the recommended NOTE: If the above-named plugs are spark plugs. not available, consult your authorized Suzuki dealer. 7-19...
  • Page 112 Spark Plug Removal 1. Place the motorcycle on the side stand. REAR FRONT 7-20...
  • Page 113 2. Unhook the hooks. Pull off the cover. Spark Plug Cleaning 3. Pull off the spark plug caps. 4. Remove the spark plugs with a spark plug wrench. 0.7 – 0.8 mm (0.028 – 0.031 in) To maintain a hot, strong spark, keep the plugs free from carbon.
  • Page 114 Installation CAUTION CAUTION Dirt can damage your engine if it A crossthreaded or overtightened enters an open spark plug hole. spark plug will damage the aluminum threads of the cylinder head. Cover the spark plug hole whenever the spark plug is removed. Follow the procedure below to tighten the spark plug properly.
  • Page 115: Engine Oil

    ENGINE OIL WARNING Long engine life depends much on the selection of a quality oil and the periodic Exhaust pipes can be hot enough to changing of the oil. Daily oil level burn you. checks and periodic changes are two of the most important maintenance items Use gloves to avoid burns.
  • Page 116 5. Hold the motorcycle vertically. Insert ENGINE OIL AND FILTER CHANGE the oil dipstick through the oil filler Change the engine oil and oil filter at hole. The oil filler cap threads should the scheduled times. The engine should not be run in but should be touching always be warm when the engine oil is the filler hole upper edge.
  • Page 117  WARNING Engine oil and exhaust pipes can be hot enough to burn you. Wait until the engine oil drain plug and exhaust pipes are cool enough to touch with bare hands before draining oil. 3. Remove the drain plug from the bot- tom of the engine and drain the engine oil into a drain pan.
  • Page 118  WARNING New and used oil can be hazardous. Children and pets may be harmed by swallowing used oil. Repeated, prolonged contact with used engine oil may cause skin can- cer. Brief contact with used oil may irritate skin. Oil filter wrench (Part No.
  • Page 119 4. Turn the oil filter with a Suzuki “cap 5. Wipe off the mounting surface on the type” oil filter wrench or a “strap engine where the new filter will be type” filter wrench of the proper size seated with a clean rag.
  • Page 120 CAUTION Using an oil filter with the wrong design or thread specifications can cause oil leaks or engine damage. Use a genuine SUZUKI oil filter or an equivalent filter designed for your motorcycle. 7-28...
  • Page 121 8. Mark the top dead center position on the “cap type” filter wrench or on the Mark top dead center oil filter. Use an oil filter wrench to tighten the filter 2 turns or to speci- fied torque. Oil filter wrench Oil filter tightening torque: 20 N·m (2.0 kgf-m, 14.5 lbf-ft) 9.
  • Page 122 NOTE: About 3000 ml (3.2 US qt) of oil will be required when changing oil only. CAUTION Engine damage may occur if you use oil that does not meet SUZUKI’s specifications. Use the oil specified in the FUEL, OIL COOLANT RECOMMENDA- TIONS section.
  • Page 123: Throttle Cable Adjustment

    THROTTLE CABLE ADJUSTMENT To adjust the cable play: 1. Loosen the lock nut 1. 2. Turn the adjuster 2 so that the throt- tle grip has 2.0 – 4.0 mm (0.08 – 0.16 in) play. 3. Tighten the lock nut 1. ...
  • Page 124: Engine Idle Speed Inspection

    NOTE: If the engine idle speed is not to the SEAT LOCK section. within the specified range, ask your Suzuki dealer or a qualified mechanic to inspect and repair the motorcycle. 2. Remove the bolt 1. Raise the rear end of the fuel tank and slide it back- ward.
  • Page 125 3. Disconnect the coupler 2. 4. Inspect the fuel hose for damage and fuel leakage. If any defects are found, the fuel hose must be replaced. NOTE: Lifting up the fuel tank too much can result in the fuel hose becoming bent or twisted.
  • Page 126: Clutch Adjustment

    CLUTCH ADJUSTMENT Major Adjustment Clutch cable play should be 10 – 15 mm (0.4 – 0.6 in) measured at the clutch lever end. Adjust clutch cable play according to the following procedure: Minor Adjustment 1. Remove the 3 bolts. Remove the cover.
  • Page 127 NOTE: Any maintenance of the clutch other than the clutch cable play adjust- ment should be performed by your Suzuki dealer. 2. Loosen the lock nuts 3 and turn the nuts to obtain the correct clutch lever play.
  • Page 128: Engine Coolant

    ENGINE COOLANT To add mixed coolant: 1. Place the motorcycle on the side Coolant level stand. 2. Remove the cover by referring to the SUSPENSION ADJUSTMENT sec- tion. The engine coolant solution should be between the “F” (full) and “L” (low) level lines on the engine coolant reservoir.
  • Page 129 NOTE: Adding only water will dilute the  WARNING engine coolant and reduce its effective- ness. Add a 50:50 mixture of engine Engine coolant is harmful or fatal if coolant and water. swallowed or inhaled. Do not drink antifreeze or coolant solution.
  • Page 130: Final Gear Oil

    FINAL GEAR OIL 4. Reinstall the drain plug and tighten it securely after all the oil has been Change the gear oil as follows: drained out. Hold the motorcycle 1. Place the motorcycle on the side vertically and pour fresh oil through stand.
  • Page 131  WARNING  WARNING Operating the motorcycle with too lit- New and used oil can be hazardous. tle final gear oil can cause the final Children and pets may be harmed by drive unit to lock up and cause an swallowing used oil.
  • Page 132: Brakes

    BRAKES NOTE: Operating in mud, water, sand or other extreme conditions can cause This motorcycle has front and rear disk accelerated brake wear. If you operate brakes. your motorcycle under these conditions,  WARNING the brakes must be inspected more often than recommended in the MAIN- TENANCE SCHEDULE.
  • Page 133 Use only DOT4 brake fluid from a sealed container. Never use or mix different types of brake fluid. If there is frequent loss of fluid, take your motorcycle to a SUZUKI dealer REAR or a qualified mechanic for inspec- tion.
  • Page 134  WARNING CAUTION Brake fluid is harmful or fatal if swal- Spilled brake fluid can damage lowed, and harmful if it comes in painted surfaces and plastic parts. contact with skin or eyes. Avoid spilling any fluid when filling If swallowed, do not induce vomiting. the reservoir.
  • Page 135 Brake Pads FRONT REAR Inspect the front and rear brake pads to FRONT see if they are worn down to the grooved wear limit lines 1. If a front or rear pad is worn to the grooved wear limit line, both front or both rear pads must be replaced with new ones.
  • Page 136 Inspect brake pad wear before each Before riding, “pump” the brake use. Ask your SUZUKI dealer or a lever/pedal repeatedly until brake qualified mechanic to replace brake pads are pressed against the brake pads if any pad is worn to the limit.
  • Page 137 Rear Brake Pedal Adjustment The rear brake pedal position must be properly adjusted at all times or the disk  WARNING brake pads will rub against the disk causing damage to the pads and to the A hot muffler can burn you. The muf- disk surface.
  • Page 138 Follow the steps in this section to adjust the brake pedal properly. NOTE: Apply a drop of SUZUKI THREAD LOCK “1322” to the front foot- rest mounting bolt 1. 7-46...
  • Page 139: Tires

    Front footrest mounting bolt TIRES tightening torque:  WARNING 50 N·m (5.0 kgf-m, 36.0 lbf-ft) Failure to follow these warnings may Rear Brake Light Switch result in an accident due to tire failure. The tires on your motorcycle form the crucial link between your motorcycle and the road.
  • Page 140 Tire Pressure and Loading  WARNING Proper tire pressure and proper tire loading are important factors. Overload- Failure to perform break-in of the ing your tires can lead to tire failure and tires could cause tire slip and loss of loss of motorcycle control.
  • Page 141 Under-inflated tires make smooth cor- Tire Condition and Type nering difficult, and can result in rapid Tire condition and tire type affect motor- tire wear. Over-inflated tires cause a cycle performance. Cuts or cracks in smaller amount of tire to be in contact the tires can lead to tire failure and loss with the road, which can contribute to of motorcycle control.
  • Page 142 Check the condition of your tires each Whenever you replace a tire, use a tire day before you ride. Replace tires if of the size and type listed below. If you tires show visual evidence of damage, use a different size or type of tire, such as cracks or cuts, or if tread depth motorcycle handling may be adversely is less than 1.6 mm (0.06 in) front, 2.0...
  • Page 143 Tubeless tires require different service proce- • Ask your SUZUKI dealer or a quali- dures than tube tires. fied mechanic to perform tire repair, replacement, and balancing •...
  • Page 144: Side Stand/ignition Interlock System

    SIDE STAND/IGNITION INTERLOCK • Do not use an external repair plug to SYSTEM repair a puncture since the plug may work loose as a result of the corner- ing forces experienced by a motor- cycle tire. • After repairing a tire, do not exceed 80 km/h (50 mph) for the first 24 hours, 130 km/h (80 mph) thereafter.
  • Page 145 This may interfere with rider control lock system is not working properly. Have your motorcycle inspected by an during a left turn. authorized Suzuki dealer or some other qualified service mechanic. Check the side stand/ignition inter- lock system for proper operation before riding.
  • Page 146: Front Wheel Removal

    3. Loosen the axle holder bolts 2. mounting bolts 1 on each of the cal- Loosen the axle 3 temporarily. ipers. NOTE: A special tool is necessary to loosen the axle. The special tool is avail- able from a Suzuki dealer. 7-54...
  • Page 147 4. Place an accessory service stand or equivalent under the swing arm to help stabilize the rear end. Carefully position a jack under the engine or chassis tubes and raise the jack until the front wheel is slightly off the ground.
  • Page 148 7. To reinstall the wheel assembly, reverse the sequence described above. 8. After installing the wheel, apply the front brake several times to restore the proper lever stroke.  WARNING Failure to extend brake pads after installing the wheel can cause poor 6.
  • Page 149 If you are not sure of installed incorrectly. the proper procedure, have your authorized SUZUKI dealer or a quali- Install the front wheel in the speci- fied mechanic do this. fied direction, as indicated by the arrow on the sidewall of the tire.
  • Page 150: Rear Wheel Removal

    REAR WHEEL REMOVAL  WARNING Removing the rear wheel without use of an accessory stand can result in your motorcycle falling over and being damaged. Do not attempt road side removal of 2. Remove the cap. the rear wheel. Only remove the rear wheel at a properly equipped servic- ing facility using an accessory ser- vice stand.
  • Page 151  WARNING A hot muffler can burn you. The muf- fler will be hot enough to burn you for some time after stopping the engine. Wait until the muffler cools to avoid burns. 5. Draw out the axle. 4. Place an accessory service stand or equivalent under the swingarm or chassis tubes to stabilize the rear end.
  • Page 152 7. Remove the wheel from the splined drive gear and set the wheel assem- bly on the ground. 8. Pull the wheel assembly rearward. 9. To replace the wheel reverse the complete sequence described above. 6. Remove the brake caliper bracket mounting bolt 2.
  • Page 153 94 N·m (9.4 kgf-m, 68.0 lbf-ft) lead to an accident. NOTE: Apply a drop of SUZUKI THREAD LOCK “1322” to the rear Torque bolts and nuts to the proper brake caliper bracket mounting bolt 2.
  • Page 154: Light Bulb Replacement

    LIGHT BULB REPLACEMENT Headlight To replace the headlight bulb, perform The wattage rating of each bulb is the following steps: shown in the following chart. When replacing a burned out bulb, always use the same wattage rating. CAUTION Using a light bulb with the wrong wattage rating can cause electrical system damage or shorten bulb life.
  • Page 155 CAUTION Oil from your skin may damage the headlight bulb or shorten its life. Grasp the new bulb with a clean cloth. 3. To replace headlight bulb, reverse the above sequence. 2. Unhook the bulb holder spring 3, and pull out the bulb 4. 7-63...
  • Page 156 Headlight Beam Adjustment The headlight beam can be adjusted both up and down or right and left if necessary. To adjust the beam right and left: Insert 5 mm hexagon wrench as shown and turn the adjuster clockwise or coun- terclockwise.
  • Page 157 Turn Signal Lights To replace the turn signal light bulbs, follow these directions. 3. Push in on the bulb 2, turn it to the left, and pull it out. 4. To fit the replacement bulb, push it in and turn it to the right while pushing. 1.
  • Page 158 License Plate Light CAUTION To replace the license plate light bulb, follow the procedure steps: Overtightening the screws when reinstalling the lens may cause the lens to crack. Tighten the screws only until they are snug. 1. Remove the nuts 1. 7-66...
  • Page 159 2. Remove the screws 2 and take off 3. Push in on the bulb, twisting it to the the cover with the lens 3. left, and pull it out. 4. To fit the replacement bulb, push it in and twist it to the right while pushing. 7-67...
  • Page 160: Fuses

    FUSES FUSES MAIN FUSE The fuses are located under the seat. Two spare fuses (10A and one 15A) are provided in the fuse box. The main fuse is located under the seat. One 30A spare fuse is located in the fuse box. 7-68...
  • Page 161 • 10A SIGNAL fuse protects the run- consult your SUZUKI dealer or a ning light, horn, speedometer, turn qualified mechanic immediately. signal light, license light, stop lamp and taillight.
  • Page 163: Troubleshooting

    TROUBLESHOOTING FUEL SUPPLY CHECK ..........................8-2 IGNITION SYSTEM CHECK ........................8-3...
  • Page 164: Troubleshooting

    “FI”, showing signs of trouble in the fuel CAUTION injection system, take your machine to Failure to troubleshoot a problem an authorized Suzuki dealer. Refer to the “INSTRUMENT PANEL” section for correctly can damage your motorcy- an explanation of fuel injection system cle.
  • Page 165 If the ignition system is operating properly, a blue spark should jump across the spark plug gap. If there is still no spark, take your motorcycle to an authorized Suzuki dealer.
  • Page 166 “FI”, showing signs of trouble in the shock or an explosion. fuel injection system, take your machine to an authorized Suzuki Avoid performing this check if you dealer. Refer to the “INSTRUMENT PANEL” section for an explanation of are not familiar with this procedure, fuel injection system indicator.
  • Page 167: Storage Procedure And Motorcycle Cleaning

    STORAGE PROCEDURE AND MOTORCYCLE CLEANING STORAGE PROCEDURE ........................... 9-2 PROCEDURE FOR RETURNING TO SERVICE ..................9-4 CORROSION PREVENTION ........................9-4 MOTORCYCLE CLEANING ........................9-6 INSPECTION AFTER CLEANING ......................9-8...
  • Page 168: Storage Procedure

    Suzuki dealer. If you wish to 2. Run the engine for a few minutes service the machine for storage your- until the stabilized gasoline fills the self, follow the general guidelines fuel injection system.
  • Page 169 ENGINE TIRES 1. Pour one tablespoon of motor oil into Inflate the tires to the normal specifica- each spark plug hole. Reinstall the tions. spark plugs and crank the engine a few times. EXTERNAL 2. Drain the engine oil thoroughly and •...
  • Page 170: Procedure For Returning To Service

    PROCEDURE FOR RETURNING TO CORROSION PREVENTION SERVICE It is important to take good care of your motorcycle to protect it from corrosion 1. Clean the entire motorcycle. and keep it looking new for years to 2. Remove the oily rags from the air come.
  • Page 171 Suzuki dealer make the repair. ish. Remove these types of deposits • Store your motorcycle in a dry, well- as quickly as possible. If these ventilated area.
  • Page 172: Motorcycle Cleaning

    Your Suzuki 2. Wash the entire motorcycle with mild dealer can help you select the right detergent or car wash soap using a cover for your motorcycle.
  • Page 173 CAUTION CAUTION Radiator fins can be damaged by High pressure washers and parts spraying high pressure water on cleaner can damage your motorcy- them. cle. Do not spray high pressure water on Do not use high pressure washers to the radiator. clean your motorcycle.
  • Page 174: Inspection After Cleaning

    5. Check carefully for damage to INSPECTION AFTER CLEANING painted surfaces. If there is any For extended life of your motorcycle, damage, obtain “touch-up” paint and lubricate according GENERAL “touch-up” the damage. LUBRICATION section.  WARNING CAUTION Cleaning with any alkaline or strong Wet brakes can cause poor braking acid cleaner gasoline, brake fluid, or performance and may lead to an...
  • Page 175: Consumer Information

    CONSUMER INFORMATION EMISSION CONTROL WARRANTY ......................10-2 TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED ............. 10-3 ON-BOARD MOTORCYCLE COMPUTER DATA INFORMATION ............10-4 SERIAL NUMBER LOCATION ......................... 10-5 REPORTING SAFETY DEFECTS ......................10-6 LOCATION OF LABELS .......................... 10-7 10-1...
  • Page 176: Emission Control Warranty

    Distance EMISSION CONTROL WARRANTY 12000 km Class I 50 to 169 cc (7456 miles) Suzuki Motor Corporation warrants to the ultimate purchaser and each subse- 18000 km Class II 170 to 279 cc (11185 miles) quent purchaser that this vehicle is...
  • Page 177: Tampering With Noise Control System Prohibited

    Whenever replacing parts on your motorcycle, Suzuki recommends that you use genuine Suzuki replacement parts or their equivalent. 10-3...
  • Page 178: On-board Motorcycle Computer Data Information

    • Emission-related components and SUZUKI collects or receives data, engine parameters such as engine SUZUKI may use the data for research speed and throttle position are moni- conducted by SUZUKI, make the data tored to provide emission control available for outside research if need is...
  • Page 179: Serial Number Location

    You also need these numbers to help your authorized Suzuki dealer when you order parts. The frame number 1 is stamped on the steering head as shown in the illustra- tion. The engine serial number 2 is stamped on the crankcase assembly.
  • Page 180: Reporting Safety Defects

    Suzuki Motor Corp. If NHTSA receives similar complaints, it To contact American Suzuki, owners in may open an investigation, and if it finds the continental United States can call that a safety defect exists in a group of...
  • Page 181: Location Of Labels

    LOCATION OF LABELS Read and follow all of the warnings WARNING labeled on your motorcycle. Make sure you understand all of the labels. Keep Failure to follow these safety the labels on your motorcycle. Do not precautions may increase your risk remove them for any reason.
  • Page 182 The owner’s manual contains important safety information and instructions which should be read carefully before operating the vehicle. If the vehicle has been resold, obtain the owner’s manual from the previous owner or contact your local SUZUKI dealer for assistance. 10-8...
  • Page 183 DUAL RIDING SOLO RIDING COLD TIRE PRESSURE kgf/cm kgf/cm Check tire condition, FRONT 2.50 2.50 wear, and cold tire REAR 2.50 2.90 pressure before each ride. Replace only with FRONT REAR TUBELESS tires of listed size and type. TIRE SIZE 120/70ZR18M/C (59W) 200/50ZR17M/C (75W) Read owner’s manual for TYPE...
  • Page 184: Specifications

    SPECIFICATIONS DIMENSIONS AND CURB MASS Overall length ............... 2390 mm (94.1 in) Overall width................. 870 mm (34.3 in) Overall height ............... 1100 mm (43.3 in) Wheelbase ................1690 mm (66.5 in) Ground clearance..............145 mm (5.7 in) Seat height ................716 mm (28.2 in) Curb mass ................
  • Page 185 DRIVE TRAIN Clutch ................... Wet multi-plate type Transmission ................ 5-speed constant mesh Gearshift pattern ..............1-down, 4-up Primary reduction ratio ............1.407 (76/54) Gear ratios, Low ..............2.187 (35/16) 2nd ..............1.400 (28/20) 3rd ..............1.038 (27/26) 4rd ..............0.875 (28/32) Top..............
  • Page 186 ELECTRICAL Ignition type ................Electronic ignition (Transistorized) Spark plug ................NGK CR6E or DENSO U20ESR-N Battery.................. 12V 64.8kC (18Ah)/10HR Generator ................Three-phase A.C. Generator Main fuse................30A Fuse ..................10/10/10/10/15/15A Headlight ................12V 60/55W (H4) Brake light/Taillight..............LED Front turn signal light............12V 21/5W Rear turn signal light ............
  • Page 187 CAPACITIES Fuel tank................18.0 L (4.8 US gal) Engine oil, without filter change ......... 3000 ml (3.2 US qt) With filter change..........3200 ml (3.4 US qt) Final gear oil................. 200 – 220 ml (6.8 – 7.4 US oz) Engine coolant..............2.7 L (2.9 US qt)
  • Page 188: Index

  • Page 195 WARNING Failure to follow these safety precautions may increase your risk of injury: Wear a helmet, eye protec- tion, and bright protective clothing. Don’t ride after consuming alcohol or other drugs. Slow down on slippery sur- faces, unfamiliar terrain, or when visibility is reduced.

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